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KTM 105 SX manual

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Table of contents for the manual

  • Page 1

    SP AREP ARTS MANUAL 20 0 4 ERSA TZTEILKA T ALOG: F AHRGESTELL + MOTOR SP ARE P ARTS MANUAL: CHASSIS + ENGINE 105 SX[...]

  • Page 2

    [...]

  • Page 3

    INHAL TSVERZEICHNIS INDEX 1 2 LOCTITE 243 LOCTITE 243 ct dm do dt ep ep fk fm fm fp fp fp fp fp ht ik il il ip iq ir jk jm jm jo 1 2 bn bo dq dq dq dr ek eo fl fm fn fo fo gr gs gs hk #, # 4 do 7 bm bm bq bq ck ck cs cs dk dk dl fr gs gt ik il im io #, # br 1 4 8 bp bq br bs bt cq 9 l s jm gk gl gn hk hl ik ck ck cm cm ek ek em en ep eq er fk fl fl[...]

  • Page 4

    INHAL TSVERZEICHNIS INDEX 1 bs cp cq dk dl hl hl ik il im in jk #1 #2 #3 #1, #2, #3, #4 #4 cl hm ip cm cm cm cm 5 7 8 ck cq cr dp en ep eq fk fm fo #1, #2 #2 #1 7 8 bk bl ck cn cn cp cs ct dq ep eq eq es et fk fm fn fo fp fr fs ft gl go gr gs hp ip jm jn jp js js dk LOCTITE 243 LOCTITE 243 bm bm 1 2 bs bt ck cl cm cn cn co cp cq cr dt fm fn fr hk h[...]

  • Page 5

    INHAL TSVERZEICHNIS INDEX 1 2 3 4 5 bk 6 bl bp bq br cq cs fo fs gp gs hk js 8 go 2 3 5 9 bo bp bq br br bs bs ck cn co cp ct dk dl dm dn do el fk LOCTITE 243 LOCTITE 243 7 8 9 ck ck ck ck ck co cp do dp en ep fm fm HOLZGABEL SELBSTGEFERTIGT WOODEN FORK PLATE HOME MADE 5 9 6 bl bm dk dr bo bq fk fl bn fl fm fn fp ft fo hq hk hp LOCTITE 243 LOCTITE [...]

  • Page 6

    TELEGABEL WP USD 43 FRONT FORK WP USD 43 105 1 2 X D LOCTITE 243 LOCTITE 243 ct dm do ds ds dt ep ep fk fm fm fp fp fp fp fp fp fp fp fp ht ik il il ip iq ir jk jm jm jo 03-470.01.0 4 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 0518.Y740LS GABELBEIN LI. 4357 85 SX 04 FORK LEG L/S 4357 85SX 04 1 2 0518.Y740RS GABELBEIN RE. 4357 85 SX 04 FORK LE[...]

  • Page 7

    GABELBEINE WP USD 43 FORK LEGS WP USD 43 105 5 6 bm bn bp bq br bs bt cm cn co dk dl dn do dp dr ds dt em eo ep er et fk fk fl fm fp fs ft gn go gt hk hl hm hn ho hp hq ht ik il im in gm en (#) (#) (#) (#) (#) (#) (#) (#) jt 2 3 7 bk bl 5 6 1 8 9 4 gk gl #2 #2, gm #1, gm #1 04-470.01.1 5 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 4357.0216S V[...]

  • Page 8

    GABELBEINE WP USD 43 FORK LEGS WP USD 43 105 5 6 bm bn bp bq br bs bt cm cn co dk dl dn do dp dr ds dt em eo ep er et fk fk fl fm fp fs ft gn go gt hk hl hm hn ho hp hq ht ik il im in gm en (#) (#) (#) (#) (#) (#) (#) (#) jt 2 3 7 bk bl 5 6 1 8 9 4 gk gl #2 #2, gm #1, gm #1 04-470.01.1 6 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 49 4860.0062 K[...]

  • Page 9

    LENKER, ARMA TUREN HANDLEBAR, CONTROLS 105 1 3 bk ck dk dl dm dn do dp dq dr ds dt el eo it jl fm gn go bq 03-470.02.0 7 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 470.02.001.000 LENKER D=22MM 85 SX 2003 HANDLEBAR D=22MM 85 SX 2003 1 3 502.02.003.000 DREHGRIFFÜBERZUG DOMINO SCHW . TWIST GRIP COVER DOMINO BLACK 1 10 503.02.010.000 GASDREHGRIF[...]

  • Page 10

    HANDBREMSZYLINDER HAND BRAKE CYLINDER 105 1 2 3 4 5 7 8 9 bk 6 bn bn ck cp ik #1, #2 #1 #2 cm bq 04-461.13.0 8 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 470.13.001.000 HANDBREMSZYLINDER KPL.85 SX 03 HAND BRAKE CYL. CPL. 85 SX 03 1 2 470.13.002.000 BREMSHEBEL LOSE 85 SX 2003 BRAKE LEVER LOOSE 85 SX 2003 1 3 470.13.003.000 ZYLINDERDECKEL KPL. [...]

  • Page 11

    RAHMEN, AUSLEGER FRAME, SUB FRAME 105 1 2 bn bo dq dq dq dr ek el em en eo fl fm fn fo fo gr gs gs hk #, # 4 do 04-470.03.0 9 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 470.03.001.000 RAHMEN 85 SX „W3“ 03 FRAME 85 SX 2003 1 2 470.03.002.044 AUSLEGER 85 SX (B3) 03 SUB FRAME 85 SX (B3) 03 1 4 546.06.004.000 VERSCHLUSSKAPPE 37MM PLUG 37MM 2 [...]

  • Page 12

    FUSSBREMSBETÄTIGUNG REAR BRAKE CONTROL 105 gk gl gm gn hk hl hl ik ck ck cm cm ek ek em en ep eq er fk fl fl fp fq LOCTITE 243 #, # fm gp gq gq cn 04-470.13.1 10 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 20 0015 050123 SK.BUNDSCHRAUBE M 5X12 SW=8 HH COLLAR SCREW M 5X12 WS=8 2 22 0015 060203 SK.BUNDSCHRAUBE M 6X20 SW=8 HH COLLAR SCREW M 6X20 W[...]

  • Page 13

    SCHWINGARM, FEDERBEIN SWINGARM, SHOCK ABSORBER 105 1 3 3 5 bp bq dk dl dl dm dm dn dn dn do do do dp dp dp dr el em ft gk gl gp gq gt hk hl hm hn hq hr hr L = 401 MM #, # 5 gm co 04-470.04.0 11 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 1518.Y706 MONOSHOCK 4618 PDS 85 SX 04 MONOSHOCK 4618 PDS 85 SX 04 1 3 0015 120556 SK.BUNDSCHRAUBE M12X55 SW[...]

  • Page 14

    FEDERBEIN WP ZERLEGT SHOCK ABSORBER WP DISASSEMBLED 105 1 2 3 4 5 8 6 5 4 3 bl bo bq bp bm bn bl bs bt ck cl dq dp in in ek en cp cr ct dk ep es et fk fl er eq fo fs fq fr gk gl go gm gp gq hm ip iq ir is jk im il ik hr hs hq hp hp ho ho hn jr hn ht js 04-470.04.1 12 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 4618.0348 FEDERBEINGEH. OBEN H40 [...]

  • Page 15

    FEDERBEIN WP ZERLEGT SHOCK ABSORBER WP DISASSEMBLED 105 1 2 3 4 5 8 6 5 4 3 bl bo bq bp bm bn bl bs bt ck cl dq dp in in ek en cp cr ct dk ep es et fk fl er eq fo fs fq fr gk gl go gm gp gq hm ip iq ir is jk im il ik hr hs hq hp hp ho ho hn jr hn ht js 04-470.04.1 13 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 54 4681.0495 SCHEIBE 12X34X0,20 SHI[...]

  • Page 16

    AUSPUFF ANLAGE EXHAUST SYSTEM 105 160 GRAMM 7 bm bm bq bq ck ck ck cm cs cs dk dk dl dl dm fr gs gs gt gt gt ht ik ik il il im im io io #, # br 03-470.05.0 14 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 7 470.05.007.000 AUSPUFF 85 SX 2003 EXHAUST PIPE 85 SX 2003 1 12 503.05.012.000 SCHWINGELEMENT FÜR AUSPUFF SWINGELEMENT FOR EXHAUST PIPE 2 16 5[...]

  • Page 17

    LUFTFIL TERKASTEN AIR FIL TER BOX 105 1 3 4 8 bk bp bq br bs bt cq 9 7 7 bl ck fs jm 03-470.06.0 15 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 470.06.001.051 FIL TERW AND 85 SX 2003 FIL TER WALL 85 SX 2003 1 3 470.06.003.000 LUFTFIL TERDECKEL 85 SX 2003 FIL TER BOX COVER 85 SX 2003 1 4 470.06.001.052 KASTENHINTERTEIL 85 SX 2003 REAR PAR T FIL[...]

  • Page 18

    T ANK, SITZBANK, VERKLEIDUNG T ANK, SEA T , COVER 105 # #, 5 5 8 8 9 6 bl bn bo bo bo br br bs ck ck ck cm cm cm cm ek el fk ik 03-470.07.0 16 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 5 503.07.005.000 BENZINHAHN MIKUNI ON/OFF 2001 GAS COCK MIKUNI ON/OFF 2001 1 6 0770 130023 O-RING 13,00X2,30 O-RING 13,00X2,30 1 8 490.07.008.044 T ANKVERSCHLUS[...]

  • Page 19

    MASKE, KOTFLÜGEL MASK, FENDERS 105 7 bk bn bt ck cl cm dk dl dm dp dk 04-470.08.0 17 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 7 470.08.007.000/04 ST ARTNUMMERT AFEL 85 SX 2003 NUMBER PLA TE 85 SX 2003 1 10 470.08.010.000/04 KOTFLÜGEL VORNE 85 SX 2003 FENDER FRONT 85 SX 2003 1 13 470.08.013.000/04 HECKTEIL 85 SX 2003 REAR P ART 85 SX 2003 1 [...]

  • Page 20

    DEKOR DECAL 105 1 04-475.08.1 18 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 475.08.099.000 DEKORSA TZ 105 SX 2004 DECAL SET 105 SX 2004 1 * = NEUTEIL / NEW P ART X = NACH BEDARF / AS REQUIRED 04-475.08.1 2004[...]

  • Page 21

    VORDERRAD FRONT WHEEL 105 LOCTITE 243 1 bk bk bl bm bm bn bn bo bo fp gk hk hk hm hm hn hn il in iq it jk jl 03-470.09.0 19 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 470.09.001.144 VORDERRAD ET 85 SX 19" 03 FRONT WHEEL SP 85 SX 19" 03 1 10 470.09.010.044/96 VORDERRADNABE KPL. 85 SX 03 FRONT WHEEL HUB CPL. 85 SX 03 1 11 470.09.011.0[...]

  • Page 22

    BREMSZANGE VORNE FORMULA BRAKE CALIPER FRONT FORMULA 105 LOCTITE 243 bk bl bl bp ck cl cn cp dk hk hk hp in il #1 #2 #3 #1, #2, #3, #4 #4 bs ip 03-470.13.2 20 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 10 470.13.010.000 BREMSSCHLAUCH VORNE 85 SX 03 BRAKE HOSE FRONT 85 SX 03 1 11 0770 080019 O-RING 8,00X1,00 EPDM O-RING 8,00X1,00 EPDM 2 15 470.1[...]

  • Page 23

    HINTERRAD REAR WHEEL 105 bk bl bn bn bo bo bp bq bq dk dk ek ek fl fm fn gk gm gp gq hk hm io ip ir it jk jl 1 bk hk hm hn hn 03-470.10.0 21 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 470.10.001.244 HINTERRAD ET 85 SX 16" 03 REAR WHEEL SP 85 SX 16" 03 1 10 470.10.010.044/96 HINTERRADNABE KPL. 85 SX 03 REAR WHEEL HUB CPL. 85 SX 03 1 [...]

  • Page 24

    BREMSZANGE HINTEN FORMULA BRAKE CALIPER REAR FORMULA 105 bs cp cq dk dl hk hl hl hl ik il im in jk #1 #2 #3 #1, #2, #3, #4 #4 cl hm ip cm cm cm cm 04-470.13.3 22 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 18 461.13.018.000 HAL TEFEDER 65 SX RET AINING SPRING 65 SX 1 21 470.13.021.000 KAPPE FÜR ENTLÜFTUNGSSCHRAUBE CAP FOR BLEEDER SCREW 1 22 47[...]

  • Page 25

    MOTORGEHÄUSE ENGINE CASE 105 1 2 bs bt ck cl cm cn cn co cp cq cr dt fm fn fr hk hq hr hr hr hr hs jt #1 #1, #2, #2 hl hn hn fq fr hn hn hn hn hn ho ho ho ho hp hp hp hp hp hp hp hp im hk 03-470.30.0 23 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 470.30.000.044 MOTORGEHÄUSE KPL. 85 SX 2003 ENGINE CASE CPL. 85 SX 2003 1 2 470.30.001.000 KUPPL[...]

  • Page 26

    MEMBRANGEHÄUSE REED V AL VE CASE 105 LOCTITE 243 #1 #2 #1, #2 LOCTITE 243 et fk fl fm fp gk 03-470.30.1 24 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 49 470.30.049.000 ANSAUGFLANSCHDICHTUNG 85 SX 03 GASKET FOR INT AKE FLANGE 85 SX 1 50 470.30.050.000 ANSAUGFLANSCH 85 SX 2003 INT AKE FLANGE 85 SX 2003 1 51 470.30.051.044 MEMBRANGEHÄUSE KPL. 85[...]

  • Page 27

    KURBEL WELLE, KOLBEN CRANKSHAFT , PISTON 105 7 bp bq br bs cr cs ct dk dm dm dn do ho hp hq hr im in LOCTITE 243 03-470.30.2 25 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 7 475.30.007.000/ I KOLBEN I KPL. 105 SX 52MM 04 PISTON I CPL. 105 SX 52MM 04 1 7 475.30.007.000/ II KOLBEN II KPL. 105 SX 52MM 04 PISTON II CPL. 105 SX 52MM 04 1 15 470.30.01[...]

  • Page 28

    ZYLINDER CYLINDER 105 5 7 8 ck cq cr dp en ep eq fk fm fo #1, #2 #2 #1 04-475.30.3 26 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 5 475.30.005.044 ZYLINDER MIT FLANSCH 105 SX 04 CYLINDER WITH FLANGE 105 SX 04 1 7 470.37.007.000 STEUERDECKEL 85 SX 2003 CONTROL COVER 85 SX 2003 1 8 470.37.008.000 DICHTUNG F . STEUERDECKEL 2003 GASKET FOR CONTROL C[...]

  • Page 29

    AUSLASSSTEUERUNG EXHAUST CONTROL 105 7 8 bk bl ck cn cn cp cq cs ct dq ep eq eq es et fk fm fn fo fp fr fs ft gl go gp gq gr gs hp ip jm jn jp js js dk LOCTITE 243 LOCTITE 243 LOCTITE 243 bm bm 04-470.37.0 27 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 7 546.37.070.200 VERSCHLUSSDECKEL 2003 CLOSING COVER 2003 1 8 0770 020200 O-RING 21,95X1,78 NB[...]

  • Page 30

    VERGASER KEIHIN PWK 28 CARBURETOR KEIHIN PWK 28 105 1 2 7 8 9 bk bl bm bm bn bo bp br bs bt ck cl cm cn cp cq cr cs ct dk dl do dp dr ds ds ds ds ek ek ek eo eq eq eq eq ACHTUNG !!! V or dem Einbau des V ergasers, Bedüsung kontr ollieren. CAUTION !!! Before mounting the carburetor , check the jetting. 03-470.31.0 28 FIG TEILNR/P ARTNR BEZEICHNUNG [...]

  • Page 31

    ZÜNDANLAGE IGNITION SYSTEM 105 2 4 bk 6 bp br dl jn 3 dk jp ek bs 03-470.39.0 29 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 2 470.30.002.000 ZÜNDUNGSDECKEL 85 SX 2003 IGNITION COVER 85 SX 2003 1 3 461.39.002.100 ZÜNDANLAGE KPL. 65 SX 2003 IGNITION CPL. 65 SX 2003 1 4 461.39.004.000 ST A TOR 65/85 SX 2003 ST A TOR 65/85 SX 2003 1 6 461.39.006[...]

  • Page 32

    KUPPLUNG CLUTCH 105 1 2 3 4 5 7 bk 6 bl bp bq br ck cq cs fo fs gl gp gq gs hk hk js 8 go hl 03-470.32.0 30 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 470.32.001.044 KUPPLUNGSKORB KPL. 85 SX 03 OUTER CLUTCH HUB CPL. 85 SX 03 1 2 470.32.002.000 MITNEHMER 85 SX 2003 INNER CLUTCH HUB 85 SX 2003 1 3 470.32.003.000 DRUCKKAPPE 85 SX 2003 PRESSURE C[...]

  • Page 33

    KICKST AR TER KICKST ARTER 105 dl es fk fl fm fn fp fq ft fo hq hk hp LOCTITE 243 LOCTITE 243 gs gt 04-470.33.0 31 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 31 470.33.040.000 ANLAUFSCHEIBE 15X25X1 STOP DISC 15X25X1 1 48 0471 190120 SICHERUNGSRING DIN0471-19X1,2 CIRCLIP DIN0471-19X1,2 1 50 470.33.050.000 KICKST ARTERWELLE 85 SX 2003 KICKST ART [...]

  • Page 34

    GETRIEBE I - ANTRIEBSWELLE TRANSMISSION I - MAIN SHAFT 105 1 7 8 9 bk cp cq dp ek el el hs em LOCTITE 243 03-470.33.1 32 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 470.33.001.000 ANTRIEBSWELLE 11-Z 85 SX 2003 MAIN SHAFT 11-T 85 SX 2003 1 7 470.33.007.000 LOSRAD 5.G. 21-Z 03 IDLER GEAR 5TH G. 21-T 03 1 8 470.33.008.000 SCHIEBERAD 3./4.G. 16/19[...]

  • Page 35

    GETRIEBE II - ABTRIEBSWELLE TRANSMISSION II - COUNTERSHAFT 105 3 bl bm bn bo bp bq ck cm cn cr cs ct dk dl dm dq dq dq em en en en 03-470.33.2 33 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 3 470.33.003.000 ABTRIEBSWELLE 85 SX 2003 COUNTERSHAFT 85 SX 2003 1 11 470.33.011.000 LOSRAD 2.G. 28-Z 03 IDLER GEAR 2ND G. 28-T 03 1 12 470.33.012.000 SCHIE[...]

  • Page 36

    SCHAL TUNG SHIFTING MECHANISM 105 1 2 3 5 9 bk bl bm bn bo bp bq br br br bs bs bs bs bt ck cl cn co cp ct dk dl dm dn do el fk LOCTITE 243 LOCTITE 243 LOCTITE 243 03-470.34.0 34 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 470.34.001.000 SCHAL TGABEL 5./6. GANG 2003 SHIFT FORK 5TH/6TH GEAR 2003 1 2 470.34.002.000 SCHAL TGABEL 2./3. GANG 2003 S[...]

  • Page 37

    KÜHLSYSTEM COOLING SYSTEM 105 7 8 9 ck ck ck ck ck ck co cp do dp en en ep ep fm fm 03-470.35.0 35 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 7 470.35.007.000 KÜHLER LINKS 85 SX 2003 RADIA TOR L/S 85 SX 2003 1 8 470.35.008.000 KÜHLER RECHTS 85 SX 2003 RADIA TOR R/S 85 SX 2003 1 9 590.35.009.000 KÜHLERVERSCHLUSS 1,4 BAR 2003 RADIA T .CAP 20,[...]

  • Page 38

    SPEZIAL WERKZEUGE SPECIAL TOOLS 105 HOLZGABEL SELBSTGEFERTIGT WOODEN FORK PLATE HOME MADE 3 5 9 6 bl bm dk dr bo bq fk fl bn 04-470.29.0 36 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 3 470.29.003.000 KUPPLUNGSHAL TER 85 SX 2003 CLUTCH HOLDER 85 SX 2003 1 56 899 785 LOCTITE 243 BLAU 6CCM LOCTITE 243 BLUE 6CCM 1 6 470.29.006.000 EINSTELLLEHRE 85 [...]

  • Page 39

    [...]

  • Page 40

    KTM-Sportmotorcycle AG A–5230 Mattighofen www .ktm.at KTM Group Partner Art.NR.: 3.208.117 01/2004 Foto: Mitterbauer 3208117[...]